Milanese mesh rolling

ABSTRACT

A flexible Milanese mesh material is disclosed herein. Particularly, the Milanese mesh material may have a structure that is conducive to a more flexible mesh material. The Milanese mesh may be formed from rows of wire spirals having a flexibility improving cross-section. The flexibility of the Milanese mesh may be improved by applying a secondary finishing process to the Milanese mesh. The finishing process may include continuously rolling the Milanese mesh around and/or against a mandrel such that the Milanese mesh product forms a smaller loop around the mandrel as the flexibility of the Milanese mesh product improves.

TECHNICAL FIELD

This disclosure relates generally to a wire mesh, and more particularly to a Milanese wire mesh and individual wire coils which provide a highly flexible mesh carpet, and methods and apparatuses for manufacturing the same.

BACKGROUND

A Milanese mesh structure (sometimes called a “carpet”), as illustrated for example in FIG. 1A, is a decorative mesh typically made from multiple metallic spiral wires threaded together. The wire utilized in forming the spirals, as illustrated for example in FIG. 1B. typically has a circular cross-section as illustrated, for example, in FIG. 1C. The mesh carpet is sometimes used to make necklaces, bracelets, or other decorative accessories.

Typically, a spool containing a straight wire material is set into a machine, The machine runs the wire material into a mandrel apparatus that forms the wire material into a spiral. The spiral is then forced forward and cut off at a certain length. After this, the machine makes the next spiral. This new spiral is then threaded into an already existing cutoff spiral. Once threaded the machine cuts off the new spiral. This process is continually repeated until a mesh carpet is formed.

Once the mesh carpet is formed, it is cut into various shapes depending on the end product. Typically, the product is formed of relatively short pieces of mesh. The pieces of mesh may be manually bound into a long strip utilizing another spiral of equal strength to join the discrete pieces together. The edges may then be processed to remove sharp and uneven coil ends. In this form the mesh is unstable as the individual coils can be removed. As such, the material may be locked so that the individual coils movement is significantly limited and the mesh carpet is secure. The locking is accomplished by pressing the strip flat and thus deforming the shape of the round coils.

Once locked, the mesh may be further processed to provide flexibility. The mesh may pass through a machine with cylinders that oscillate or otherwise move up and down, thereby forcing the mesh strip to bend back and forth. This treatment makes the mesh flexible but also often leaves visible lines in the mesh from contact with the internal cylinders of the machine.

Other processing steps may be used to improve the overall aesthetics of the mesh. For example, a folding clasp and/or end pieces may be formed by stamping the ends. The mesh strips may also undergo a polishing to enhance their appearance.

Typical manufacturing process for Milanese mesh devices do not allow mesh carpets that are created to be flexible without the crimping of the mesh and or introduction of the intervening binding and locking coils discussed above. Thus, there is a need for a improved method for forming a Milanese mesh product.

SUMMARY

Generally, embodiments disclosed herein may include apparatuses and methods for forming a flexible mesh carpet. The mesh carpet may be made flexible in a variety of ways. For example, the coils of the mesh carpet may be preformed to have a particular cross-section in order to manufacture a flexible mesh carpet. In another example, the mesh carpet may be processed after manufacture in order to improve the flexibility. Additionally the various examples may be combined to achieve greater flexibility, e.g. a mesh carpet made from preformed coils may undergo additional processing to further improve the flexibility. In the various embodiments and examples the mesh carpet may be a Milanese mesh carpet.

In one embodiment, a flexible mesh carpet may include a first wire coil. The first wire which makes up the coil may have a first surface and a second surface which oppose one another. The first surface and the second surface may be connected by surfaces that substantially form partial arcs (e.g. of a circle or ellipsis). The mesh carpet may also include a second wire coil threaded into the first wire coil. One of the surfaces from the first wire coil may contact a surface on the second wire coil. The first wire coil and the second wire coil may form two rows of the mesh carpet. In one example, the first surface and the second surface in the first wire coil may be opposing flat surfaces positioned at an acute angle from one another. Alternatively they may be positioned at an obtuse angle from one another. In another example, the first surface and the second surface may be concave surfaces. The concave surfaces may have a profile that approximately matches the second wire coil surface. In another example, the wire may have a triangular cross-section. In such and example, the first surface and the second surface may be opposing flat surfaces positioned at an angle to one another connected by another flat surface.

In another embodiment, the flexibility of a mesh carpet may be improved by wrapping the mesh carpet around a first mandrel having a circumference smaller than natural mesh flexibility circumference of the mesh carpet. The first end of the mesh carpet may be constrained in a fixed or moveable restraint. The second end of the mesh carpet may be constrained in a movable restraint. The mesh carpet may then be moved back and forth around the first mandrel forming a smaller mesh flexibility circumference without the mesh carpet being impacted by the first mandrel or additional mandrels, The finishing process may include continuously rolling the Milanese mesh around or against the mandrel such that the Milanese mesh carpet forms a smaller loop around the mandrel as the flexibility of the Milanese mesh product improves.

The finishing process may include compressing the mesh carpet between two restraining plates such that the restraining plates contact the mesh carpet decreasing the bend radius and thereby improving the flexibility of the mesh carpet. Another embodiment may take the form of utilizing a coil with a specific wire cross-section and providing a secondary finishing process to the mesh carpet. The mesh carpet may be moved to a smaller mandrel after a substantial portion of the mesh carpet has moved around the first mandrel.

In accordance with one embodiment, the mesh carpet may be wrapped around a first mandrel. Contact may be made between the mesh carpet and the first mandrel. The mesh carpet may be moved back and forth across the mandrel. The mesh carpet may be moved to a smaller mandrel. The mesh carpet may be moved back and forth across the smaller mandrel. This may continue to subsequent mandrels such as a third or fourth mandrel. The method may end once an improved or desired flexibility is achieved in the mesh carpet.

In accordance with one embodiment, a mesh carpet may be wrapped around a first mandrel. Contact may be made or maintained between the mesh carpet and the first mandrel. The mesh carpet may be wrapped around a second mandrel. The mesh carpet may also be additionally wrapped around other mandrels such as third mandrel and weaved between them in a zigzag path. The mesh carpet may be translated in a first direction causing both sides of the mesh carpet to contact and bend against each of the mandrels. The mesh carpet may be translated in a second direction in addition to the first direction. Alternatively the mesh carpet may be continuously translated in the same direction and not back and forth.

It is to be understood that both the foregoing general description and the following detailed description are for purposes of example and explanation and do not necessarily limit the present disclosure. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate subject matter of the disclosure. Together, the descriptions and the drawings serve to explain the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows an example of a prior art strip of Milanese mesh.

FIG. 1B shows an example of an isometric view of a prior art Milanese mesh wire coil.

FIG. 1C shows an example of a cross-section view of a prior art Milanese mesh wire coil.

FIG. 2A shows an example of an isometric view of Milanese mesh wire coil with flat surfaces,

FIG. 2B shows an example of a cross-section view of a Milanese mesh wire coil with flat surfaces.

FIG. 3A shows an example of an isometric view of Milanese mesh wire coil with concave surfaces.

FIG. 3B shows an example of a cross-section view of a Milanese mesh wire coil with concave surfaces.

FIG. 4A shows an example of an isometric view of Milanese mesh wire coil that is triangular.

FIG. 4B shows an example of a cross-section view of a Milanese mesh wire coil that is triangular.

FIG. 5 is a schematic view of an example of a massaging machine for improving the flexibility of a mesh carpet as known in the art.

FIG. 6 is a schematic view of an example of a system for improving the flexibility of a mesh carpet.

FIG. 7A-C is a schematic view of an example of a system for improving the flexibility of a mesh carpet.

FIG. 8 is a schematic view of an example of a system for improving the flexibility of a mesh carpet.

FIG. 9 is a flow chart illustrating an example method of improving the flexibility in a mesh carpet utilizing preformed coils.

FIG. 10 is a flow chart illustrating an example method of improving the flexibility in a mesh carpet utilizing restraint plates.

FIG. 11 is a flow chart illustrating an example method of improving the flexibility in a mesh carpet utilizing multiple mandrels.

FIG. 12 is a flow chart illustrating an example method of improving the flexibility in a mesh carpet utilizing offset mandrels.

DETAILED DESCRIPTION

Generally, embodiments disclosed herein may take the form of a flexible mesh carpet and methods for forming the same. In various embodiments and examples the mesh carpet may be a Milanese mesh carpet. The mesh carpet may have a structure that is formed by a flexible mesh material. One embodiment may take the form of a mesh carpet being formed from rows of preformed coils. The coils may be pre-formed with a specific cross-section (e.g., shape) of wire that improves or enhances the flexibility of the mesh carpet. Examples of cross-sections include wires that have flat sides, concave sides, or are generally triangular. Certain cross-sections may allow an improved flexibility in the mesh carpet over a traditional circular wire cross-section. Utilizing preformed wires may improve mesh carpet flexibility without requiring a secondary process to enhance flexibility, for example, by deforming, stretching or manipulating the constituent wires.

Another embodiment may take the form of applying a secondary finishing process to a mesh carpet. The finishing process may include continuously rolling the Milanese mesh around or against a mandrel such that the Milanese mesh carpet forms a smaller loop around the mandrel as the flexibility of the Milanese mesh product improves. The finishing process may include compressing the mesh carpet between two restraining plates such that the restraining plates contact the mesh carpet, decreasing its bend radius, and thereby improving the flexibility of the mesh carpet. Multiple size mandrels may be used. Mandrels may also be offset from one another, allowing both sides of a mesh carpet to be worked simultaneously. Another embodiment may utilize a coil with a specific wire cross-sectional shape to form the mesh carpet, and may provide a secondary finishing process to the mesh carpet.

As indicated above, a Milanese mesh carpet, shown for example in FIG. 1A, is a decorative mesh typically made from a plurality coils with the plurality of coils threaded together. The wire utilized in coil 110, as illustrated for example in FIG. 1B, traditionally has a circular cross-section 108 with a single circumferential exterior surface 106 as illustrated in FIG. 1C. However, once the Milanese mesh carpet is formed, the circular cross-section of the wire coils limits the flexibility of the mesh carpet insofar as the bend radius of the coils is limited. To improve the flexibility of a mesh carpet when compared to one formed with circular cross-sectional wire coils, coils with flexibility improving (e.g., non-circular) cross-sectional shapes may be utilized. FIGS. 2-4 illustrate examples of these flexibility improving cross-sections.

In one embodiment and as illustrated in FIGS. 2A and 2B, a coil 200 may have a non-circular major exterior surface. The major exterior surface as shown in FIG. 2B is the perimeter of the cross-section 201 of wire 200, which may define a plurality of exterior surfaces. For example, the plurality of exterior surfaces may include a first flat surface 204 and a second flat surface 208. As one example, the first flat surface 204 and the second flat surface 208 may be formed on opposing sides of an axis running through the cross-section and may taper toward that axis and thus toward one another

In various embodiments, the flat surfaces 204/208 may be positioned relative to one another at one of an acute angle, an obtuse angle or parallel. The first flat surface 204 and the second flat surface 208 may be connected by an outward-facing surface 202 (“outward surface”) and an inward-facing surface 206 (“inward surface”). It should be appreciated that these outward and inward orientations are provided with respect to an axis running along the length of the coiled wire, e.g., an axis about which the wire coils.

Outward surface 202 may connect with the first flat surface 204 along surface interface 203 and with the second flat surface 208 at surface interface 209. Inward surface 206 may connect with the first flat surface 204 at surface interface 205 and with the second flat surface 208 at surface interface 207. The surface interfaces 203, 205, 207, 209 may be abrupt transitions defined by a line extending along the wire 201 at the transition (as shown in FIG. 2B) or the interfaces may be rounded transitions between surfaces. In accordance with various embodiments, the inward surface 206 and the outward surface 202 may be different sizes relative to one another. For example, the inward surface 206 may be wider than the outward surface 202. Alternatively, the inward surface 206 may be narrower than the outward surface 202 (as shown in FIG. 2B). In another example, the inward surface 206 may be the same as the outward surface 202.

The surfaces 202, 204, 206, 208, may be oriented with respect to the helical structure of the coil 200 in order to reduce the interference contact between one coil and any adjacent coils woven into a mesh carpet. In accordance with one embodiment, the inward surface 206 may point toward a center axis 220 of the coil 200. Stated another way, inward surface 206 may be the portion of the wire that is most proximate to the center axis 220 of the coil 200. Conversely, outward surface 202 may be the portion of the wire that is most distal to the center axis 220 of the coil 200. In this configuration, the outward surface forms the exterior of coil 200 and the inward surface 206 forms the interior surface of the coil 200.

In another embodiment, as illustrated in FIGS. 3A and 3B, a coil 300 may have a flexibility improving major exterior surface. The major exterior surface as shown in FIG. 3B is the perimeter of the cross-section 301 of wire 300 which may include a plurality of exterior surfaces. The plurality of exterior surfaces may include a first concave surface 304 and a second concave surface 308. The first concave surface 304 and the second concave surface 308 may oppose one another. In various embodiments, the concave surfaces 304 and 308 may be positioned relative to one another at one of an acute angle, an obtuse angle or parallel. The first concave surface 304 and the second concave surface 308 may be connected by an outward surface 302 and an inward surface 306. Outward surface 302 may connect with the first concave surface 304 along surface interface 303. Outward surface 302 may connect with the second concave surface 308 at surface interface 309. Inward surface 306 may connect with the first concave surface 304 at surface interface 305. Inward surface 306 may connect with the second concave surface 308 at surface interface 307. The surface interfaces 303, 305, 307, and 309 may be lines where the surfaces come to a point or the surface interfaces 303, 305, 307, and 309 may be round transitions between surfaces. (as shown in FIG. 3B) In accordance with various embodiments, the inward surface 306 and the outward surface 302 may be different sizes relative to one another. For example, the inward surface 306 may be wider than the outward surface 302. Alternatively, the inward surface 306 may be narrower than the outward surface 302 (as shown in FIG. 3B). In another example, the inward surface 306 may be the same as the outward surface 302.

Similar to the surfaces of coil 200, the surfaces 302, 304, 306, 308, of coil 300 may be oriented to the helical structure of the coil 300 in order to reduce the interference contact between one coil and any adjacent coils when woven into a mesh carpet. In accordance with one embodiment, the inward surface 306 may point toward a center axis 320 of the coil 300. Stated another way, inward surface 306 may be the portion of the wire that is most proximate to the center axis 320 of the coil 300. Conversely, outward surface 302 may be the portion of the wire that is most distal to the center axis 320 of the coil 300. In this configuration, the outward surface forms the exterior of coil 300 and the inward surface 306 forms the interior surface of the coil 300.

In another embodiment, as illustrated in FIGS. 4A and 4B, a coil 400 may have a flexibility improving major exterior surface. The major exterior surface as shown in FIG. 4B is the perimeter of the cross-section 401 of wire 400 which may include a plurality of exterior surfaces. The plurality of exterior surfaces may include a first flat surface 404 and a second flat surface 406. The first flat surface 404 and the second flat surface 406 may oppose one another. In various embodiments, the flat surfaces 404 and 406 may be positioned relative to one another at one of an acute angle or an obtuse angle. The first flat surface 404 and the second flat surface 406 may be connected by a surface 402. Surface 402 may connect with the first flat surface 404 along a first surface interface 403. Surface 402 may connect with the second flat surface 406 at a second surface interface 407. First flat surface 404 and second flat surface 406 may connect at a third surface interface 405. The surface interfaces 403, 405, and 407 may be lines where the surfaces come to a point or the interfaces may be round transitions between surfaces.

The surfaces 402, 404, or 406 may be oriented with respect to the helical structure of the coil 400 in order to reduce the interference contact between one coil and any adjacent coils when woven into a mesh carpet. In accordance with one embodiment, the surface interface 405 may point toward a center axis 420 of the coil 400. Stated another way, the surface interface 405 may be the portion of the wire that is most proximate to the center axis 420 of the coil 400. Conversely, outward surface 402 may be the portion of the wire that is most distal to the center axis 420 of the coil 400. In this configuration, the outward surface forms the exterior of coil 400 and the surface interface 405 forms the interior surface of the coil 400. In another embodiment, the opposite may be true. The surface interface 405 may be the portion of the wire that is most distal to the center axis 420 of the coil 400, Surface 402 may be the portion of the wire that is most proximal to the center axis 420 of the coil 400. In this configuration, the surface 402 forms the exterior of coil 400 and the surface interface 405 forms the interior surface of the coil 400.

While each of the wires in the forgoing examples and embodiments are illustrated and discussed as being symmetric, this is not required. For example, one half of a wire cross-section may include a flat surface as shown in the left half of FIG. 2B or FIG. 4B and one half of a wire cross-section may include a concave surface as shown in right half of FIG. 3B. Any combination of surfaces, symmetries, and wire cross-section designs may be utilized to improve the flexibility of the mesh carpet. As such, one of ordinary skill in the art may recognize that each of the embodiments or examples discussed herein may be combined in order to form a wire cross-section that achieves the flexibility goals of the mesh carpet. While only limited examples are provided herein, all forms of wire cross-sections that may be coiled and wire cross-sections that improve the flexibility of the mesh carpet are contemplated herein.

In order to form coils having a wire with a flexibility improving cross-section, the wire with the cross-section may first be formed. The wire cross-sections may be formed by, for example, by drawing the wire through a die with the particular cross-section embedded in the die. The output wire from the drawing die may then include the flexibility improving cross-section. Alternatively, the wire cross-sections may, be formed by, for example, rolling the wire between two mandrels having the particular cross-section. The output wire from the rolling process may then include the flexibility improving cross-section. These particular wire cross-sections may be formed prior to or during coiling of the wire coils. For example, the drawn wire may be fed directly onto a coiling mandrel. Alternatively, the coiling mandrel may include a cross-section forming die such that as the wire is coiled onto the mandrel, the wire can be forced (by either a rolling press or similar device) into the mandrel die obtaining the particular wire shape. It should be recognized that the flexibility improving cross-section may be applied to the wires under any circumstances or by any process known to one of ordinary skill in the art.

It should also be understood that the term wire does not necessarily apply strictly to elongated metallic strands. As used herein, the term wire may refer to any pliable strand or rod of material made in any diameter or length suitable for winding into a coil for use in forming a mesh carpet. The coils may be formed from a variety of different materials. For example, ferromagnetic or non-ferromagnetic (e.g. paramagnetic and diamagnetic) metals may be utilized including iron, nickel cobalt, chromium, manganese, ferromagnetic stainless steel (e.g., 400 series stainless steel), copper, silver, gold, aluminum and non-ferromagnetic stainless steel (e.g., 300 series stainless steel) or any other ferromagnetic or non-ferromagnetic material as well, The various materials may be utilized for corrosion resistance, magnetic characteristics, conductive characteristics, aesthetics, weight, or workability. In other embodiments, some of the coils may be non-metallic materials including polymers, carbon fibers, or natural fibers capable of being formed in and holding a coil shape. These non-metallic materials may be utilized for insulating properties, weight, cost, or other desirable properties. Therefore, in the context of this application, the terms “coil” and “wire” may include forms made of metallic or non-metallic materials.

Although a mesh carpet's flexibility may be improved by pre-forming a particular wire cross-section, flexibility may also be improved without requiring a particular wire cross-section. Other flexibility improving procedures include processing the mesh carpet after it has been formed. When originally formed, the mesh carpet may have a natural circumference providing a default mesh flexibility. This “mesh flexibility circumference” may be understood as the unforced shape the mesh carpet makes when bent, which may define a minimum bend radius for the carpet. By forcing a formed mesh carpet into a smaller mesh flexibility circumference, the mesh carpet flexibility may be improved. Traditionally the process has been performed by a massaging machine as shown in FIG. 5. A massaging machine may have a plurality of cylinders (500, 501, and 502) that gyrate up and down (e.g. along arrows a, b, and c respectively) impacting the mesh carpet 100. The mesh carpet 100 is moved between the cylinders.

As discussed above, this process may create aesthetically unpleasing marks on the mesh carpet. Further, such marks may be failure points or weak points for the mesh carpet. Typically the marks are in the form of visual transverse lines across the strip of mesh. In accordance with various embodiments, a system and method for improving flexibility of a mesh carpet may also be utilized without leaving behind impact marks. Such a system and method for improving flexibility of a mesh carpet may be utilized without impacting the mesh carpet.

In accordance with various embodiments and as shown in FIGS. 6-8, the flexibility of a mesh carpet may be improved by wrapping the mesh carpet around a mandrel. Wrapping as used herein may include more than minimal contact but instead may include the mesh carpet traveling a significant distance around the circumference of the mandrel, For example, wrapping the mesh carpet may include the carpet traveling around at least 50 percent of the circumference of the mandrel. Alternatively, wrapping the mesh carpet may include the carpet traveling around 0-25 percent, 25-50 percent, 50-75 percent, or greater than 75 percent, of the circumference of the mandrel. To improve the flexibility of the mesh carpet, the mandrel may have a smaller radius than the natural circumference of the mesh carpet. Forcing the mesh carpet around this smaller radius may improve the flexibility of the mesh carpet. Contact between the mandrel and the mesh carpet may also be maintained. Maintaining the contact may prevent localized distortion in the mesh carpet from contact with the mandrel. Instead, any distortion that occurs, to improve the flexibility of the mesh carpet, may be continuous across the length of the mesh carpet and not localized, In accordance with the various embodiments as discussed herein, various apparatuses may be utilized to improve the flexibility of the mesh carpet.

In accordance with one embodiment, as shown in FIG. 6, a mesh carpet 100 may be wrapped around mandrel 600. The mandrel 600 or the mesh carpet 100 may be movable. For example, as shown in FIG. 6 mandrel 600 may be movable in more than one direction such as along to arrow c. The mandrel 600 may be supported in a guide 604 that enables the travel of mandrel 600. In one embodiment, the mandrel 600 may rotate according to arrow d in FIG. 6 around a pivot 602. The rotation of the mandrel 600 may allow a static contact between the mesh carpet 100 and the exterior surface of the mandrel 600. The static contact may reduce abrasions or deformations that may otherwise result from the mesh carpet 100 sliding across the mandrel 600. Alternatively, the mandrel 600 may be stationary allowing carpet 600 to slide across the mandrel.

As indicated, the mesh carpet 100 may be movable. Particularly one or more of an end 110 or 120 of the mesh carpet 100 may be movable. Moving the ends 110 or 120 in opposite direction may cause the mesh carpet 100 to move back and forth around mandrel 600. Similarly, as illustrated in FIG. 6, moving the first end 110 and retaining the second end 120 may allow the mesh carpet 100 to move back and forth around mandrel 600 with mandrel 600 be movable as well. A fixed position retaining device 620 may be utilized to retain the second end 120 in place. It may be noted that a restraint may be any device operable to hold an end of the mesh carpet such that resistance may be applied to the movement of the mesh carpet. For example, the restraint may be a clamp, bracket, weight, or the force applied by a person holding the end of the mesh carpet. The restraint may be fixed limiting movement of the mesh carpet. For example, a clamping force indicated by arrows e may be exerted against second end 120. As shown, a clamp may retain that end in place. The first end 110 may have a movable restraint 630. The movable restraint 630 may be operable to change locations allowing the first end 110 of the mesh carpet 100 to move relative to the second end 120. The movable restraint 630 may be operative to receive a force from, for example, a cable 610 placing the mesh carpet 100 in tension. In various embodiments, this may be a constant tension. The tension may increase or decrease. For example, in response to a sufficient force applied to the movable restraint 630, the movable restraint 630 may cause the mesh carpet 100 to move. When the sufficient force is applied to movable restraint 630, the mandrel may be operable to move in the direction of the movable restraint 630. Once the mandrel 600 has made a full travel toward second end 120, the mandrel may drive the carpet back in the other direction, In this manner the apparatus is operable to have the mandrel drive in one direction forcing the first end 110 of the carpet 100 toward the mandrel 600 while the mandrel 600 travels away from the second end 120 of the mesh carpet 100. This motion causes the mesh carpet 100 to travel around the mandrel 600. Then the movable restraint 630 may receive a force from cable 610 drawing the first end 110 of the mesh carpet 100 in the opposite direction of the mandrel 600 and pulling the mandrel 600 in the same direction. This enables the apparatus to work the mesh carpet 100 back and forth across mandrel 600.

In accordance with various embodiments, the mandrel 600 may be smaller than the natural mesh flexibility circumference of mesh carpet 100. Working the mesh carpet 100 back and forth around the mandrel 600 may cause the mesh flexibility circumference of the mesh carpet 100 to adapt to the circumference of the mandrel 600. However, additional forces may aid in causing the mesh carpet 100 to adapt to the circumference of the mandrel 600. In accordance with one embodiment, the mandrel 600 and the mesh carpet 100 may be retained between a first plate 640 and a second plate 650. The mesh carpet 100 may contact a first surface 642 on the first plate and a second surface 652 on the second plate. The first plate 640 or the second plate 650 may be movable toward or away from the other plate as indicated by arrows a and b in FIG. 6. By moving the first plate 640 and the second plate 650 closer together, the contact between the mesh carpet 100 and the surface of the plates (642 and 652) may force the mesh carpet 100 into a smaller mesh flexibility circumference. This motion between the plates may be continuously driven as the mesh carpet 100 works back and forth around mandrel 600. Alternatively, this motion may be controlled such that after a certain amount of time of the mesh carpet 100 working back and forth around mandrel 600, the distance between the first plate 640 and the second plate 650 may decreases in an incremental amount. This decrease may force the mesh flexibility circumference to adapt to the circumference of the mandrel, thus allowing the plates to move even closer and closer together. Once the mesh flexibility circumference of the mesh carpet 100 substantially matches the mandrel 600 circumference, a smaller mandrel can be placed in the system and the process can continue. The plate force and working the mesh carpet 100 around the mandrel circumference can be continued until the desired mesh flexibility circumference is achieved.

In accordance with various embodiments, the mandrel 600 or the plates 640 and 650 may be configured to reduce any surface abrasion or deformation on the mesh carpet 100 due to contact with the mandrel 600 or the plates 640 and 650. For example, the mandrel 600 or the plates 640 and 650 may have a low friction surface. Alternatively or in addition to, the mandrel 600 or the plates 640 and 650 may be made of a softer surface material than mesh carpet 100. Examples of low friction surfaces may include nylon, polyoxymethylene, polished steal, a lubricated surface or any similar low friction material or process for reducing the friction of a surface. Similarly the nylon or polyoxymethylene or other polymers may be a softer material than mesh carpet 100 limiting their ability to scratch a harder surface. It should be appreciated that a person of ordinary skill in the art may select other known or developed materials accordingly.

In another embodiment, as illustrated in FIG. 7A-C, an apparatus may include a plurality of mandrels 700, 710, and 720 for improving the flexibility of a mesh carpet. Similar to other embodiments as discussed herein, the mandrels 700, 710, or 720 may be rotatable (along arrow c as shown in FIG. 7A-C) about pivots 701, 711, and 721 respectively or the mandrels 700, 710, or 720 may be fixed. Mandrels 700, 710, or 720 may have mesh carpet 100 wrapped around the mandrels. Each end of the mesh carpet may be movably restrained. The first end of the mesh carpet may be movable along arrow a (as shown in FIG. 7A-C). The second end of the mesh carpet may be movable along arrow b (as shown in FIG. 7A-C). Placing a force on one end of the mesh carpet 100 and allowing the other end of the mesh carpet 100 to move allows the mesh carpet to move back and forth around the mandrel. As such, this apparatus may allow the mesh flexibility circumference of mesh carpet 100 to conform to the circumference of the mandrel. It may be noted that after working the mesh carpet across a first mandrel, a second smaller mandrel may be used to further increase the flexibility of the mesh carpet. As such, mandrel 710 may be smaller in diameter than mandrel 700 and mandrel 720 may be smaller in diameter than mandrel 710.

In another embodiment, as illustrated in FIG. 8, an apparatus may improving the flexibility of a mesh carpet by winding the mesh carpet through a series of mandrels (e.g. mandrels 800, 810 and 820). The apparatus may include any number of mandrels such as 1, 2, 3 . . . or N different mandrels. The mandrels (e.g. 800, 810 and 820) may be fixed or rotatable around pivots (e.g. 802, 812, and 822). If rotatable, the mandrels (e.g. 800, 810 and 820) may be able to rotate clockwise or counter clockwise (e.g. according to arrows c, d, and e).

In various embodiments, the mandrels may be offset from one another. The offset may allow the mesh carpet 100 to be threaded between and wrap around each of the different mandrels (e.g. 800, 810 and 820). In one example, the mandrels (e.g. 800, 810 and 820) may be located relative to one another in a zigzag pattern as shown in FIG. 8. The mesh carpet 100 may wrap around a first mandrel 800. The mesh carpet may then wrap around a second mandrel 820 such that both sides of the mesh carpet 100 are in contact with a mandrel. The mesh carpet may wrap around a third mandrel 810. The mash carpet may be retained on both ends. A first end may be restrained by restraint 860. A second end may be restrained by restraint 870. Restraints 860 or 870 may be movable restraints. In accordance with one embodiment Restraints 860 or 870 may be operable to receive a force causing the mesh carpet to move through the mandrels. The force may alternate between restraint 860 and restraint 870. The alternating force may cause mesh carpet to move back and forth as illustrated by arrows a and b. Alternatively, the mesh carpet may be moved continuously through the mandrel pattern in the same direction.

As here may any number of mandrels in the pattern, the mesh carpet 100 may move through an apparatus with a sufficiently long path to allow the mesh carpet 100 to obtain the desired mesh flexibility circumference. To aid in this, the mandrels may decrease in size along the path of the mesh. For example, mandrel 820 may be smaller than mandrel 800.

This decrease in size may continue until the mandrel is the size operable to form the desired mesh flexibility circumference. With the mesh carpet continuing from one mandrel to another, the apparatus path that the mesh carpet 100 follows may include various guides e.g. 830, 840, and 850. The various guides (830, 840, and 850) may be operable to direct the mesh carpet 100 between mandrels, keep mesh carpet 100 from falling off the mandrels, or apply a force on mesh carpet 100 in order to conform the mesh carpet to the circumference of the mandrel.

While FIGS. 6-8 are described herein as separate embodiments, it may be noted that each of the embodiments may stand alone or be combined with other embodiments. For example, the apparatus described and exemplified in either FIG. 6 of FIG. 8 may utilize multiple sizes of mandrels as exemplified in FIG. 7.

As indicated herein a method for improving the flexibility of a mesh carpet may include using a wire with a specific surface, In accordance with one embodiment, as shown in FIG. 9 an operation 900 for making a mesh carpet with improved flexibility may start. In operation 910, a first coiled wire with a surface operable to improve the flexibility of the mesh carpet may be obtained. The wire may have a first surface and a second surface which oppose one another. The first surface and the second surface may be operable to contact the wire of other coils in a manner that improves flexibility between the adjacent coils. In operation 920 a second coiled wire may be obtained. In operation 930 the second wire may be intertwined into the first wire to form a mesh carpet. In operation 940 the first surface of the first coiled wire may contact the second coiled wire. The process may continue with intertwining additional coiled wires forming a mesh carpet. Utilizing the shape of the wires with opposing surfaces as discussed above with regard to FIGS. 2-4, the mesh carpet may be formed with flexibility superior to a mesh carpet formed with circular wires. In operation 950 the method may end.

In accordance with one embodiment, as shown in FIG. 10, an operation 1000 for improving the flexibility of a mesh carpet may start. In operation 1005, a first end of the mesh carpet may be constrained. In operation 1010, a second end of the mesh carpet may be constrained. In operation 1015, the mesh carpet may be located between a first plate and a restraint plate. In operation 1020, the mesh carpet may be wrapped around a first mandrel. In operation 1025, contact may be made between the mesh carpet and the first mandrel. In operation 1030, the first mandrel may move away from a fixed end of the mesh carpet. In operation 1035, the movable end of the mesh carpet may be moved back to an original position. In operation 1040, the mesh carpet may be contacted with the first plate and the second plate. In operation 1045 the gap between the first plate and the second plate may be decreased. In operation 1050, a smaller mesh flexibility circumference may be formed by moving the mesh carpet around the first mandrel and between the restraint plates. In operation 1055, the method may end once an improved or desired flexibility is achieved in the mesh carpet

In accordance with one embodiment, as shown in FIG. 11, an operation 1100 for improving the flexibility of a mesh carpet may start. In operation 1110, the mesh carpet may be wrapped around a first mandrel. In operation 1120, contact may be made between the mesh carpet and the first mandrel. In operation 1130, the mesh carpet may be moved back and forth across the mandrel. In operation 1140, the mesh carpet may be moved to a smaller mandrel. Alternatively, the first mandrel may be replaced with a smaller mandrel. In operation 1150, the mesh carpet may be moved back and forth across the mandrel. This may continue to subsequent mandrels such as a third or fourth mandrel. In operation 1160, the method may end once an improved or desired flexibility is achieved in the mesh carpet.

In accordance with one embodiment, as shown in FIG. 12, an operation 1200 for improving the flexibility of a mesh carpet may start. In operation 1210, the mesh carpet may be wrapped around a first mandrel. In operation 1220, contact may be made or maintained between the mesh carpet and the first mandrel. In operation 1230, the mesh carpet may be wrapped around a second mandrel. The mesh carpet may also be additionally wrapped around other mandrels such as third mandrel and weaved between them in a zigzag path. In operation 1240, the mesh carpet may be translated in a first direction causing both sides of the mesh carpet to contact and bend against each of the mandrels. In operation 1250, the mesh carpet may be translated in a second direction. Alternatively the mesh carpet may be continuously translated in the same direction and not back and forth. In operation 1260, the method may end once an improved or desired flexibility is achieved in the mesh carpet.

As used throughout this document in each of the embodiments, aspects, examples, lists and various descriptions of the subject matter contained herein, the word “or” is intended to be interpreted in its inclusive form (e.g. and/or) not in its exclusive form (e.g. only one of) unless explicitly modified to indicate only one item in a list is intended (e.g. only one of A, B, or C). For example, the phrase A, B, or C is intended to include any combination of the elements. The phrase can mean only A. The phrase can mean only B. The phrase can mean only C. The phrase can mean A and B. The phrase can mean A and C. The phrase can mean B and C. The phrase can mean A and B and C. This concept extends to any length of list (e.g. 1, 2, 3 . . . n) used herein.

Although the foregoing discussion has presented specific embodiments, the foregoing merely illustrates the principles of the invention. Persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure as various modifications and alterations to the described embodiments will be apparent to those skilled in the art, in view of the teachings herein. For example, the processing steps may be performed in another order, or in different combinations. It will thus he appreciated that those having skill in the art will be able to devise numerous systems, arrangements and methods which, although not explicitly shown or described herein, embody the principles of the disclosure and are thus within the spirit and scope of the present invention. From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustration only, and references to details of particular embodiments are not intended to limit the scope of the present invention, as defined by the appended claims. 

We claim:
 1. A mesh carpet comprising a first wire coil having a cross-section defined by a first surface and a second surface which oppose one another, with the first surface and the second surface connected by a transition surface; and a second wire coil threaded into the first wire coil such that the first surface contacts a second wire coil surface; wherein the first wire coil and the second wire coil form two rows of the mesh carpet.
 2. The mesh carpet of claim 1, wherein the first surface and the second surface are opposing flat surfaces positioned at an acute angle from one another.
 3. The mesh carpet of claim 1, wherein the first surface and the second surface are opposing flat surfaces positioned at an obtuse angle from one another.
 4. The mesh carpet of claim 1, wherein the first surface and the second surface are concave surfaces with the concave surfaces having a profile that approximately matches the second wire coil surface.
 5. The mesh carpet of claim 1, wherein: the first surface and the second surface are opposing flat surfaces positioned at an angle to one another; and a first side of the first surface and a first side of the second surface are connected by a first arc that is a portion of the cross-section of the wire that is proximal to the coil axis.
 6. The mesh carpet of claim 5, wherein: the transition surface is an arc; a second side of the first surface and a second side of the second surface are connected by a transition surface that is a second arc; and the second arc is longer than the first arc.
 7. A method of forming a mesh carpet comprising: obtaining a first coiled wire having a cross-section defined by a first surface and a second surface which oppose one another, with the first surface and the second surface connected by a transition surface; obtaining a second coiled wire; intertwining the second wire into the first wire to form a mesh carpet; and contacting the first surface with the second coiled wire.
 8. The method of claim 7, wherein the first surface and the second surface are opposing flat surfaces positioned at an angle to one another.
 9. The method of claim 7, wherein the first surface and the second surface are concave surfaces having a profile that approximately matches the second wire coil surface.
 10. The method of claim 8, wherein the operation of intertwining is accomplished by contacting the first surface with a first exterior convex surface of the second wire.
 11. The method of claim 9, wherein the operation of intertwining is accomplished by contacting the first concave surface with a first exterior convex surface of the second wire.
 12. The method of claim 7, further comprising obtaining a third wire and intertwining the third wire into the second wire.
 13. A method of improving the flexibility of a mesh carpet comprising: constraining a first end of the mesh carpet in a restraint; constraining a second end of the mesh carpet in a movable restraint; wrapping the mesh carpet around a first mandrel having a circumference smaller than natural mesh flexibility circumference; and continuously moving the mesh carpet around the first mandrel, thereby forming a smaller mesh flexibility circumference without the mesh carpet being impacted by the first mandrel or additional mandrels.
 14. The method of claim 13, wherein, as the mesh carpet continuously moves around the first mandrel, the first mandrel rotates such that the mesh carpet and any points of contact between the mesh carpet and the first mandrel are substantially stationary relative to one another, thereby preventing the mesh carpet from sliding across the circumference of the first mandrel.
 15. The method of claim 14, further comprising: moving the first mandrel away from a first end of the mesh carpet that is in a fixed restraint until a substantial portion of the mesh carpet has moved around the first mandrel; and moving the second end of the mesh carpet that is in a movable restraint in the opposite direction, thereby causing the first mandrel and the mesh carpet to move back around the first mandrel in the opposite direction until the first mandrel has returned to an original location.
 16. The method of claim 15, further comprising locating the mesh carpet between a first restraint plate and a second restraint plate as the mesh carpet is moved around the first mandrel.
 17. The method of claim 16, further comprising: contacting the mesh carpet with the first restraint plate; and moving the first restraint plate closer to the second restraint plate after a substantial portion of the mesh carpet has moved around the first mandrel at least once, thereby causing the circumference of the mesh carpet to be compressed between the first restraint plate and the second restraint plate.
 18. The method of claim 13, further comprising moving the mesh carpet to a smaller mandrel after a substantial portion of the mesh carpet has moved around the first mandrel.
 19. The method of claim 18 wherein as the mesh carpet continuously moves around the mandrel, the mandrel is stationary causing the mesh carpet to slide across the circumference of the mandrel.
 20. The method of claim 13, further comprising: wrapping the mesh carpet around a second mandrel and a third mandrel such that the mesh carpet occupies a zigzag pattern across the first mandrel, second mandrel, and third mandrel; and driving the mesh carpet back and forth through the path of the first mandrel, second mandrel, and third mandrel.
 21. An apparatus for improving the flexibility of a mesh carpet, comprising: a first mandrel having a circumference smaller than natural mesh flexibility circumference; a first restraint attached to the first end of the mesh carpet; a second restraint attached to the second end of the mesh carpet and the second restraint is located relative to the first restraint such that the mesh carpet wraps around the first mandrel.
 22. The method of claim 21, wherein: the first mandrel rotates such that as the mesh carpet moves around the first mandrel the mesh carpet; and all points of contact between the mesh carpet and the first mandrel are substantially stationary relative to one another, thereby limiting the mesh carpet from sliding across the circumference of the first mandrel.
 23. The method of claim 22, wherein: the first restraint is a fixed restraint; the second restraint is a movable restraint; the first mandrel is movable laterally such that, in response to the mandrel moving, the mesh carpet is pulled around the mandrel by a static force from the first restraint; and the second restraint is configured to receive a force that moves the mesh carpet and the mandrel back to an original position.
 24. The method of claim 23, further comprising a first restraint plate and a second restraint plate, the mesh carpet and the first mandrel located between the first restraint plate and the second restraint plate.
 25. The method of claim 23, wherein: the first restraint plate contacts the mesh carpet and is configured to be movable relative to the second restraint plate, thereby allowing the gap between the first restraint plate and the second restraint plate to decrease as the circumference of the mesh carpet decreases.
 27. The method of claim 21, wherein the first mandrel is stationary causing the mesh carpet to slide across the circumference of the mandrel.
 28. The method of claim 21, further comprising a second mandrel and a third mandrel positioned relative to one another such that the mesh carpet forms a zigzag pattern as the mesh carpet is wrapped around the first mandrel, second mandrel, and third mandrel. 